Packaged product and method of manufacture

ABSTRACT

A compressible product such as a stuffed toy is formed of a memory type stuffing, such as hollow conjugate siliconized polyester fibers, optionally surrounded by an outer shell, that has an uncompressed shape at ambient atmospheric pressure. The compressible product is positioned in a packaging envelope and a pressure differential is created to deform the product into a deformed shape substantially smaller than the uncompressed shape. Optionally, a graphic on the outer shell that is visible in the uncompressed shape is obscured in the deformed shape. The packaging envelope is sealed with the compressible product in the deformed shape. When the seal is broken, the stuffing and outer shell cooperate to substantially reform the compressible product into its uncompressed shape.

FIELD OF THE INVENTION

The present invention relates to packaged products and methods ofmanufacture. More specifically, the present invention relates to methodsand devices for manufacturing and packaging deformable products.

BACKGAROUND OF THE INVENTION

It has long been recognized that one of the primary factors in the costsof shipping and storing of merchandise is the volume required on avehicle or vessel, in a warehouse, or on a store shelf. As more and morepowerful engines are used in transportation, and stronger material areused for construction, weight is becoming less of a critical factor, andmanufacturers are looking for ways to miniaturize items, in both theireventual usage form, and the form in which they are shipped and storedprior to, or in between, usage.

Some items may be reduced in size by simply packaging less. Miniaturetoiletry kits, office desk sets, and snack foods have been marketed togreat success for many years. Some items may be reduced in size bymaking more effective component parts. The current wave of personalelectronic items comes immediately to mind. Some items may be reduced insize by merely packing them better, and it is in this arena that thepresent invention is directed.

Shrink wrapping of goods is a technique well known in the art. Taunton,U.S. Pat. No. 2,778,171 disclosed “a method of evacuating an envelope”more than fifty years ago. Other inventions followed to address themethod of evacuation and the preparation of the containers, bags, andenvelopes. None of these, however dealt with the items to be containedin these containers, bags, and envelopes, nor with the configurationinto which they would be placed.

Compression of the item itself to reduce volume is also a technique wellknown in the art Merry, U.S. Pat. No. 5,172,629 discloses “a method ofcompacting a sheet article” such as a shirt or underwear, made of wovenfabric, to reduce the volumetric requirement. Earlier, Hammon, U.S. Pat.No. 2,659,935 disclosed a method of making compressed sponges.

Such prior art, however, has dealt primarily with the method ofevacuation or compression and the apparatus to perform such evacuationor compression, rather than with the item to be evacuated or compressed.Items were assumed to be either formless, such as underwear or t-shirts,or capable of retaining their general shape when compressed. There is aneed in the art for a method and device for the compression of items toreduce their space requirements, where subsequent shape recovery wouldbe automatic and fast. Likewise, there is a need in the art for a methodand device for the compression of items to reduce their spacerequirements, where the item being compressed has one, predetermined,shape when compressed, and a second, also predetermined, shape whenreleased from compression.

SUMMARY OF THE INVENTION

The present invention includes a packaged product and a method forpackaging a product. A packaged product includes a compressible productwith a flexible outer shell and a stuffing. The stuffing is formed froma compressible memory material such that the outer shell and thestuffing cooperate to form the compressible product into an uncompressedshape under ambient atmospheric pressure. In one optional embodiment,the stuffing may be hollow conjugate siliconized polyester fiber.

A packaged product also includes an airtight packaging envelope. Thepackaging envelope includes a sealable opening. The compressible productis placed within the packaging envelope. When a pressure differential iscreated inside the envelope and the opening is sealed, the compressibleproduct assumes a deformed state substantially smaller than theuncompressed shape. Optionally, the deformed state includes compressingand/or folding the compressible product. When the seal is opened, theouter shell and the stuffing cooperating to substantially reform thecompressible product to the uncompressed shape.

In an optional embodiment, the outer shell includes a graphic thereonthat is unobscured in the uncompressed shape. When the compressibleproduct is placed within the packaging envelope, the product ispositioned to obscure the graphic on the outer shell. Consequently, whenthe seal is opened, the outer shell and the stuffing cooperating tosubstantially reform the compressible product to the uncompressed shapewith the graphic unobscured. For example, in one optional embodiment,the compressible product in the uncompressed shape includes a body, ahead extending from to the body, and at least one limb extending fromthe body. In one such optional embodiment, the graphic appears on thebody, and the body is positioned in the packaging envelope with the headand/or the limb folded to obscure the graphic.

The present invention also includes a method for packaging a product anda product manufactured according to the method. According to anembodiment of the method, a flexible outer shell is provided. The outershell is stuffed with a stuffing formed from a compressible memorymaterial. Optionally, the stuffing is hollow conjugate siliconizedpolyester fiber. The outer shell and the stuffing cooperate to form acompressible product in an uncompressed shape under ambient atmosphericpressure.

An airtight packaging envelope including an a sealable opening isprovided. The compressible product is placed into the packaging envelopeand a pressure differential is created inside the envelope. Optionally,in placing the compressible product into the packaging envelope, thecompressible product may be folded and in creating a pressuredifferential, the compressible product may be compressed. The opening issealed such that the compressible product assumes a deformed stateinside the packaging envelope substantially smaller than theuncompressed shape. The packaging envelope and compressible product in adeformed state form a compressed packaged product. When the seal isopened, the outer shell and the stuffing cooperate to substantiallyreform the compressible product to the uncompressed shape.

As above, in one optional embodiment, the outer shell may include agraphic thereon that is unobscured in the uncompressed shape. In onesuch optional embodiment, the method includes positioning thecompressible product in the packaging envelope to obscure the graphic onthe outer shell such that the product is and when the seal is opened,the outer shell and the stuffing cooperating to substantially reform thecompressible product to the uncompressed shape to reveal the graphic.For example, in one optional embodiment, the compressible product in theuncompressed shape includes a body, a head extending from to the body,and at least one limb extending from the body. The graphic appears onthe body and when the compressible product is placed in the packagingenvelope, the head and/or the limb are folded to obscure the graphic.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a compressible product in an uncompressedshape according to an optional embodiment of the present invention;

FIG. 2 is a left side view of a compressible product in an uncompressedshape according to the optional embodiment of FIG. 1;

FIG. 3 is a front view of a packaged product with a compressible productaccording to the optional embodiment of FIG. 1 in a deformed shape;

FIG. 4 is a left side view of a packaged product according to theoptional embodiment of FIG. 3;

FIG. 5 is a front view of a compressible product in an uncompressedshape according to an optional embodiment of the present invention;

FIG. 6 is a front view of a packaged product with a compressible productaccording to the optional embodiment of FIG. 5 in a deformed shape;

FIG. 7 is a flow chart of a method according to an optional embodimentof the present invention.

DESCRIPTION

Reference is now made to the figures wherein like parts are referred toby like numerals throughout. The present invention is a packaged product500 that includes a compressible product 100 and a packaging envelope380. FIGS. 1 and 5 show optional embodiments of a compressible product100 according to the current invention. The compressible product 100 maytake many different forms such as a stuffed animal or toy or other plushobject. However, it is contemplated that the compressible product 100may be any item of a deformable nature.

The compressible product 100 includes a compressible stuffing having anuncompressed shape. The stuffing is formed from a compressible memorymaterial. By compressible memory material, a material is contemplatedthat may be deformed and compressed, but returns to its uncompressedshape when released. In one optional embodiment, the stuffing is hollowconjugate siliconized polyester fibers, such as 15 D 64 mm HollowConjugate Siliconized A grade polyester fibers. However, in alternateoptional embodiments, other material may be used, as long as suchmaterial is readily deformable and compressible, and capable of resumingits uncompressed shape when released.

Optionally, the stuffing is stuffed into a flexible outer shell 121 andthe stuffing and outer shell 121 cooperate to form the uncompressedshape. In such an optional embodiment, the outer shell 121 could takeany form. In an optional embodiment in which the compressible product isa stuffed animal or other plush toy, the outer shell 121 may be fabric,textile, fur, or other outer covering.

At ambient atmospheric pressure, the outer shell 121 and stuffingcooperate to form a compressible product 100 in an uncompressed shape.This uncompressed shape is distinguished from a deformed shape that isdiscussed in greater detail below and shown in FIGS. 3, 4, and 6.

In one optional embodiment, decorative imagery such as facial features111 may be included on the outer shell. In one particular embodiment,shown in FIGS. 5 and 6, a graphic 170 may be visible, i.e. unobscured,on the outer shell 121. The graphic 170 may take many different forms,but in an optional embodiment the graphic is a message, such as “HappyBirthday” or “Get Well Soon,” an image, or other visually perceptiblegraphic 170 that is displayed in a graphic area on the outer shell 121.

The compressible product may take any shape. Referring generally toFIGS. 1-6, in an optional embodiment the compressible product 100consists of a body 140 connected to a head 110 and one or more limbs120, 130, 150, 160, such as a left arm 120, a right arm 130, a left leg150, and a right leg 160. The body 140 may optionally a graphic in adesignated graphic area 170. In this optional embodiment, the limbs 120,130, 150, 160 and the head 110 are disposed about the body 140 as wouldbe expected for the semblance of a person, an animal, or a similarcreature. The head 110 exhibits facial features 111 intended to resembleeyes and a mouth. In alternate optional embodiments, facial features 111may differ, being more or less detailed, may exhibit different details,or may be omitted.

Turning to FIGS. 3 and 4, in the optional embodiment illustrated, thepackaged product 500 also includes a packaging envelope 380. In oneoptional embodiment, the packaging envelope 380 is a plastic bag,sheath, tube, or other container that can be sealed in an airtightfashion. In an optional embodiment, the packaging envelope 380 is formedfrom a flexible plastic ply that will conform to the shape of thecompressible product 100 placed inside it.

To carry out the method of the present invention, as shown in FIG. 7,the compressible product 100 provided 700 is placed 704 in the packagingenvelope 380 provided 702. In placing the 704 compressible product 100in the packaging envelope 380, the compressible product 100 may besimply inserted or, in an optional embodiment, may be positioned withinthe packaging envelope 380. For example, in one optional embodiment,shown in FIG. 6, the compressible product 100 may be folded inside thepackaging envelope 380 so it is held in a folded configuration asdiscussed in greater detail below. In one such optional embodiment, acompressible product having a graphic 170 thereon is placed in thepackaging envelope 380 with the graphic 170 obscured or hidden. Thus, inthe example discussed above in which a compressible product 100 includesa body 140 with a head 110 and limbs 120, 130, 150, 160 extendingtherefrom, a graphic 170 on the compressible product 100, such as thebody 140, may be obscured by folding the head 140 and/or one or morelimbs 120, 130, 150, 160 across the body.

Referring generally to FIGS. 3, 4, 6, and 7, a pressure differential iscreated 706 to reduce the pressure inside the packaging envelope 380below ambient atmospheric pressure. The pressure differential inside thepackaging envelope 380 causes the packaging envelope 380 to collapse,and allows ambient air pressure to compress the compressible product 100into a deformed shape substantially smaller than the uncompressed shape.Optionally, the pressure differential is created by evacuating air fromthe packaging envelope 380 through an opening. For example, air may beevacuated through the opening using a vacuum pump.

For example, in an optional embodiment in which hollow conjugatesiliconized polyester fibers fill a textile outer shell, one mayanticipate that the compressible product 100 will be reduced in volumeby approximately 80% when in its deformed shape compared to itsuncompressed shape. However, it is noted that this is exemplary onlyand, in alternate optional embodiments, such compression ratio may behigher or lower. While the optional embodiment illustrated anticipatesthat the airtight package 380 will be highly evacuated, such evacuationis not essential and in alternate optional embodiments evacuation may beto a lesser degree or omitted.

With continued reference to FIGS. 3, 4, 6, and 7, to maintain thepressure differential, the packaging envelope 380 is sealed 708. As maybe appreciated, if the compressible product 100 is positioned before thepressure differential is created, the packaging envelope 380 will holdthe compressible product 100 in position when the packaging envelope 380collapses around the compressible product 100. The seal 382 may takemany different forms, including adhesive, an interlocking seam,mechanical fasteners, or the like. In an optional embodiment in whichthe packaging envelope 380 is a flexible plastic ply, a seal may becreated by heating and crimping opposing surfaces until the ply meltsand forms a seal.

When the seal 382 is broken, the pressure inside and outside thepackaging envelope 380 reaches equilibrium and the outer shell 121 andstuffing cooperate to substantially reform the compressible product 100to its uncompressed shape. For example, in one optional embodiment inwhich the packaging envelope 380 is heat sealed, the seal 382 may bebroken by cutting-the airtight package 380. In alternate optionalembodiments, the airtight package 380 may be resealable or reformable,so that the airtight package 380 may be reused. In the optionalembodiment illustrated, the compressible product 100, once removed fromthe airtight package 380, substantially reforms itself from its deformedshape to its uncompressed shape. For example, once removed from theairtight package 380 and released, the memory-type stuffing of which thecompressible product 100 substantially reforms its uncompressed shape,so that the compressible product 100 in its deformed shape in FIGS. 3and 4 reforms itself into its uncompressed shape as shown in FIGS. 1 and2, just as the compressible product 100 in its deformed shape in FIG. 6reforms itself into its uncompressed shape as shown in FIG. 5. In anoptional embodiment of FIGS. 5 and 6 in which a graphic 170 is includedon the outer shell 121, the reforming of the uncompressed shape servesto reveal the graphic 170 that was obscured in the deformed shape.

It contemplated that the compressible product 100 may be constructed toallow repeated compression and decompression of the compressible product100.

While certain embodiments of the present invention have been shown anddescribed it is to be understood that the present invention is subjectto many modifications and changes without departing from the spirit andscope of the claims presented herein.

1. A packaged product comprising: a compressible product comprising aflexible outer shell and a stuffing, said stuffing formed from acompressible memory material such that said outer shell and saidstuffing cooperate to form said compressible product into anuncompressed shape under ambient atmospheric pressure; and an airtightpackaging envelope including a sealable opening such that when saidcompressible product is placed within said packaging envelope, apressure differential is created to reduce the pressure inside saidpackaging envelope below ambient atmospheric pressure, and said openingis sealed, said compressible product assumes a deformed statesubstantially smaller than said uncompressed shape, and when said sealis opened, said outer shell and said stuffing cooperating tosubstantially reform said compressible product to said uncompressedshape.
 2. The packaged product of claim 1 wherein said deformed stateincludes compressing said compressible product.
 3. The packaged productof claim 1 wherein said deformed state includes folding saidcompressible product.
 4. The packaged product of claim 1 wherein saidouter shell includes a graphic thereon that is unobscured in saiduncompressed shape such that when said compressible product is placedwithin said packaging envelope, said product is positioned to obscuresaid graphic on said outer shell and when said seal is opened, saidouter shell and said stuffing cooperating to substantially reform saidcompressible product to said uncompressed shape with said graphicunobscured.
 5. The packaged product of claim 4 wherein said compressibleproduct in said uncompressed shape includes a body, a head extendingfrom to said body, and at least one limb extending from said body. 6.The packaged product of claim 5 wherein said graphic appears on saidbody, and said body is positioned in said packaging envelope with one ofsaid head or said limb folded to obscure said graphic.
 7. The packagedproduct of claim 1 wherein said stuffing is hollow conjugate siliconizedpolyester fiber.
 8. A packaged product comprising: a compressibleproduct comprising a flexible outer shell and a stuffing, said stuffingformed from a compressible memory material such that said outer shelland said stuffing cooperate to form said compressible product into anuncompressed shape under ambient atmospheric pressure, said outer shellincluding a graphic thereon that is unobscured in said uncompressedshape; and an airtight packaging envelope including a sealable openingsuch that when said compressible product is placed within said packagingenvelope with said product positioned to obscure said graphic on saidouter shell, a pressure differential is created to reduce the pressureinside said packaging envelope below ambient atmospheric pressure, andsaid opening is sealed, said compressible product assumes a deformedstate substantially smaller than said uncompressed shape with saidgraphic obscured, and when said seal is opened, said outer shell andsaid stuffing cooperating to substantially reform said compressibleproduct to said uncompressed shape with said graphic unobscured.
 9. Thepackaged product of claim 8 wherein said deformed state includescompressing said compressible product.
 10. The packaged product of claim8 wherein said compressible product in said uncompressed shape includesa body, a head extending from to said body, and at least one limbextending from said body.
 11. The packaged product of claim 10 whereinsaid graphic appears on said body, and said body is positioned in saidpackaging envelope with one of said head or said limb folded to obscuresaid graphic.
 12. The packaged product of claim 8 wherein said stuffingis hollow conjugate siliconized polyester fiber.
 13. A method forpackaging a product, comprising: providing a flexible outer shell;stuffing said outer shell with a stuffing, said stuffing formed from acompressible memory material such that said outer shell and saidstuffing cooperate to form a compressible product in an uncompressedshape under ambient atmospheric pressure; providing an airtightpackaging envelope including an a sealable opening; placing saidcompressible product into said packaging envelope; creating a pressuredifferential to reduce the pressure inside said packaging envelope belowambient atmospheric pressure; and sealing said opening such that saidcompressible product assumes a deformed state inside said packagingenvelope substantially smaller than said uncompressed shape wherein thepackaging envelope and compressible product in a deformed state form acompressed packaged product, and when said seal is opened, said outershell and said stuffing cooperate to substantially reform saidcompressible product to said uncompressed shape.
 14. A compressedpackaged product manufactured by the method of claim
 13. 15. The methodof claim 13 wherein said step of creating a pressure differentialincludes compressing said compressible product.
 16. The method of claim13 wherein said step of placing said product into said packagingenvelope includes folding said compressible product.
 17. The method ofclaim 13 wherein said outer shell includes a graphic thereon that isunobscured in said uncompressed shape, said method further comprisingpositioning said compressible product in said packaging envelope toobscure said graphic on said outer shell such that said product is andwhen said seal is opened, said outer shell and said stuffing cooperatingto substantially reform said compressible product to said uncompressedshape with said graphic unobscured.
 18. The method of claim 17 whereinsaid compressible product in said uncompressed shape includes a body, ahead extending from to said body, and at least one limb extending fromsaid body.
 19. The method of claim 18 wherein said graphic appears onsaid body, said method further comprising folding one of said head orsaid limb to obscure said graphic after placing said compressibleproduct in said packaging envelope.
 20. The method of claim 13 whereinsaid stuffing is hollow conjugate siliconized polyester fiber.